Mechanical Testing and Microstructural Characterization of Hybrid Additive Manufacturing of Maraging Steel 1 and Inconel 625 Using Powder Bed Fusion and Directed Energy Deposition Processes
摘要
In this work, hybrid additive manufacturing of Maraging Steel 1 and Inconel 625 is proposed through powder bed fusion and directed energy deposition processes toward the realization of a bimaterial structure. A base structure, to impart mechanical strength and toughness, was synthesized via powder bed fusion using Maraging Steel 1. Subsequently, the directed energy deposition process was used to deposit a layer of Inconel 625, a nickel-based superalloy known for excellent corrosion and thermal resistance. The present study focuses on the mechanics and microstructural behavior of such a hybrid specimen, especially at the interface between the two materials. Tensile testing, along with microhardness profiling, was conducted for the hybrid specimen to evaluate its performance under different loading conditions. Optical microscopy combined with field emission scanning electron microscope, energy-dispersive x-ray spectroscopy, and x-ray diffraction helped cover interfacial bonding, grain structure, and phase distribution. Results showed minimal dilution and defect formation with strong metallurgical bonding at the interface. The mechanical behavior of the hybrid specimen indicated a synergistic balance between strength and thermal stability, thus likely serving high-performance applications in the aerospace, automotive, and energy sectors. The work herein therefore proves the concept of hybrid additive manufacturing toward realizing advanced engineering applications through the synthesis of dissimilar alloy properties.